Metso AAI835-H50

Technical & Performance Parameters

• Input Channel Quantity: 4 isolated 4–20 mA analog input channels
• Output Channel Quantity: 4 isolated 4–20 mA analog control output channels
• A/D / D/A Conversion Resolution: 16-bit high precision
• Input Measurement Accuracy: ±16 µA @ 20 mA full scale
• Output Control Accuracy: ±48 µA full scale
• HART Protocol Compatibility: HART 5 / HART 7 two-way digital communication
• Channel Inter-Isolation Withstand Voltage: 500 V AC, 1 minute insulation test
• Channel-System Bus Isolation Withstand Voltage: 500 V AC
• Open Circuit Detection Threshold: Input channel <0.65 mA trigger open circuit fault alarm
• Data Update Cycle: Fixed 10 ms fast refresh period for input and output signals
• Module Power Supply: 24 V DC backplane bus power supply, power consumption 4.3 W
• Operating Temperature Range: -20 °C ~ +70 °C
• Storage Temperature Range: -40 °C ~ +85 °C
• Physical Dimensions: 107.5 mm (H) × 32.8 mm (W) × 130 mm (D)
• Net Weight: 0.2 kg
• Certifications: CE, UL, CSA industrial safety certification

  Material Composition

  1. Outer frame: Black flame retardant engineering plastic injection molding shell with Metso OEM marking
  2. Main circuit board: Low-noise multi-layer FR4 PCB with full-board anti-corrosion three-proof coating
  3. Channel isolation component: Independent miniature isolation transformer for each input/output channel
  4. HART communication demodulation chip: Dedicated industrial HART 5/7 modem integrated circuit
  5. Terminal connector assembly: Gold-plated phosphor bronze spring clamp terminals compatible with Yokogawa TB terminal bases
  6. Power regulation unit: Low ripple isolated DC-DC converters for independent channel power supply
  7. Internal shock absorption pads: Silicone elastic gaskets fixed between PCB and outer plastic housing

  Structural Characteristics

  1. Compact dual-function I/O integrated design, combining analog acquisition and control output in single module
  2. Standard pluggable backplane card structure compatible with Metso BIU8 DCS racks and Yokogawa CENTUM VP backplanes
  3. Front panel dual-indicator layout: 4 input channel running/fault LEDs, 4 output channel status LEDs, dedicated HART communication indicator
  4. Full independent isolation between every input channel, output channel, and system backplane bus
  5. Vertical air convection heat dissipation grooves embedded on both sides of the plastic housing to eliminate heat accumulation
  6. Dual anti-loosening plastic locking latches on module side edges to resist long-term mechanical vibration from mining processing equipment
  7. Reserved mounting interface for standard TB37G/TB38G terminal bases for centralized field wiring

  Working Principle

  1. Field pressure, flow, level transmitters deliver 4–20 mA analog signals to the 4 input channels via shielded wiring and TB terminal bases
  2. Each input channel passes through isolated signal conditioning circuits to filter industrial frequency noise and eliminate ground loop interference
  3. 16-bit A/D converters convert analog current signals to digital measurement data; data transmits to DCS main controller via internal ESB bus every 10 ms
  4. Upper DCS system sends valve/actuator control commands to the module’s 4 output channels through backplane bus communication
  5. On-board 16-bit D/A converters convert digital control instructions to proportional 4–20 mA analog output signals for regulating field control valves and linear actuators
  6. Built-in HART modem superimposes digital communication signals onto the analog current loop, supporting bidirectional data exchange with smart HART transmitters and valve positioners
  7. Real-time self-diagnosis circuits continuously monitor input open-circuit faults (<0.65 mA), output short-circuit faults, over-range signals, and HART communication disconnection; corresponding front panel LEDs activate red alarm light upon fault detection
  8. Independent channel isolation barriers completely separate field-side high-interference mining environment circuits from internal DCS control logic circuits

  Core Function Features

  1. Integrated 4AI + 4AO all-in-one architecture, simultaneously completing process signal collection and closed-loop equipment control
  2. Native HART 5 / HART 7 bidirectional communication, enabling remote parameter calibration, fault diagnosis, and range modification of HART smart field instruments
  3. Full galvanic isolation for all input and output channels, zero signal crosstalk between measurement loops and control loops
  4. Fixed 10 ms ultra-fast signal refresh cycle to meet high-response crushing, flotation, and feeding process closed-loop control requirements
  5. Built-in open-circuit, short-circuit, and over-range fault self-diagnosis with visual front-panel alarm indication
  6. Dual-system compatibility: Fully interoperable with Metso BIU8 mining DCS platform and original Yokogawa CENTUM VP distributed control system
  7. Support dual redundant hot-swap backup configuration for critical mineral processing safety control loops
  8. Independent 19.0 V ~ 25.5 V DC loop power supply output for all two-wire field transmitters connected to input channels

  Advantage Highlights

  1. Dual I/O integration reduces total module quantity inside control cabinets, cutting rack space occupation and wiring engineering costs for mineral processing plants
  2. OEM customized Metso branded variant of Yokogawa industrial-grade hardware, 100% interchangeable with original Metso DCS spare parts without rack modification
  3. Full-channel electrical isolation effectively suppresses strong electromagnetic interference generated by mining crushers, conveyors, and high-power stirring equipment
  4. HART communication eliminates external gateway hardware, simplifying intelligent instrument management for mine automation systems
  5. Compact thin-profile design maximizes cabinet installation density for large-scale concentrator central control rooms
  6. Wide temperature operating range maintains stable measurement and control accuracy under open-air mine and high-temperature flotation workshop conditions
  7. Industrial CE, UL, CSA safety certifications compliant with global mining and metallurgy automation project standards

  Applicable Industries

  Hard rock & soft mineral mining, metal ore concentrator flotation control, aggregate crushing and screening automation, cement raw material processing, industrial mineral slurry transportation control, metallurgical smelting auxiliary process monitoring

  Installation Requirements

  1. Insert module into dedicated analog I/O slots of Metso BIU8 DCS backplane or Yokogawa CENTUM VP rack; fully engage dual side locking latches after insertion
  2. Mount matched TB37G or TB38G terminal base directly below the module for all field input/output signal wiring
  3. All field signal wiring must use shielded twisted pair cables; cable shielding layer implements single-point grounding inside the control cabinet only
  4. Maintain a minimum 10 mm vertical heat dissipation gap between adjacent modules to ensure unobstructed air convection cooling
  5. For intrinsically safe explosive hazardous mine zones, install certified HART isolation safety barriers at the front end of every input and output channel
  6. Control cabinet internal ambient temperature must remain strictly within the -20°C ~ +70°C rated operating range; forced air cooling fans are mandatory for high-temperature enclosed cabinet environments
  7. All actuator output wiring must be separated from high-voltage power cables with a minimum 30 cm physical distance to avoid analog signal distortion

  Usage Precautions

  1. Strictly prohibit connecting AC high-voltage power signals to any input or output channel terminals; this action will permanently burn internal isolation transformers and HART modem chips
  2. Do not reverse the polarity of the 24 V DC backplane power supply terminals, which causes irreversible damage to the module’s internal power regulation circuit
  3. This model carries H50 non-explosion-proof marking; direct installation inside Class I Division hazardous mining areas without additional safety barriers violates operational specifications
  4. Avoid disassembly of the plastic outer housing without professional maintenance tools; disassembly destroys integrated channel isolation structures and voids equipment performance consistency
  5. Conduct terminal base dust cleaning and wiring tightness inspection every 6 months to prevent poor contact and measurement/control signal drift
  6. If HART communication failure occurs, first verify the continuity of the 4–20 mA analog loop before replacing the module or terminal base assembly
  7. Never operate output channels beyond the 0.6 mA ~ 24 mA rated signal range; over-range operation triggers permanent D/A circuit degradation